Structural member fabricating process

ABSTRACT

A METHOD IS DISCLOSED OF HANDLING AND COMPLETELY FABRICATING STRUCTURAL STEEL FLOOR MEMBERS FROM RAW STEEL SHAPES INTO PRECISELY FITTING INTERLOCKING UNIT ELEMENTS THAT FORM WITH THE NECESSARY COLUMNS A MULTIPLE-CELL CAGE FOR THE SUPPORT OF FLOORS, ROOFS, WALLS AND OTHER ELEMENTS. IN A TYPICAL APPLICATION OF THE PROCESS A TRAILER-LOAD OR CAR-LOAD OF RAW SHAPES FROM THE STEEL ROLLING MILLS IS SHUNTED ALONGSIDE A LONGITUDINALLY-DISPOSED MULTIPLE FABRICATING APPARATUS, THAT INCLUDES A TRAVELLING HOIST OPERABLE ALONG A TANSVERSE OVERHEAD GANTRY RUNWAY SPANNING THE APPARATUS AND THE NECESSARY PARALLEL DELIVERING AND SHIPPING VEHICLES. SUCCESSIVE RAW SHAPES ARE HOISTED OUT OF THE DELIVERING VEHICLE AND LOWERED TO THE ADJACENT DUAL CONVEYOR BELTS THAT TRANSVERSELY MOVE THEM INDIVIDUALLY INTO THE OPERATING AREA OF THE DUAL END-LOCATED THREE WAY DRILLS THAT SIMULTANEOUSLY DRILL THE WEBS AND FLANGES OF THE SHAPE NEAR THE ENDS OF ATTACHMENT OF PAIRS OF END CONNECTION ANGLES TO THE WEB OF THE SHAPE. THE FLANGE HOLES PERMIT THE ATTACHMENT TO WIND-BRACING BRACKETS LOCATED ON THE SUPPORTING COLUMNS. THE INTERMEDIATELY LOCATED VERTICALLY PIVOTABLE DRILLS DRILL THE WEB FOR FLOOR BEAM CONNECTIONS. MOVED ON TO THE FORWARD HALF OF THE APPARATUS MULTIPLE RIVETS ATTACHED TO A LOWER CONNECTION ANGLE ARE HEATED, THE ANGLE IS ASSEMBLED TO THE BEAM WEB, AN UPPER MATING CONNECTION ANGLE IS PLACED OVER THE PROJECTING RIVETS AND PLURAL AIR HAMMERS HEAD THE RIVETS OVER THE THREE ASSEMBLED PIECES OF STEEL. THIS OPERATION IS PERFORMED AT EACH END OF THE SHAPE. THE NOW COMPLETED MEMBER IS LIFTED OFF THE DUAL BELTS AND STACKED IN AN EMPTY PARALLEL VEHICLE FOR OUTBOUND SHIPPING. THIS OVERALL PROCESS IS APPLICABLE TO OTHER COMBINATIONS OF DIFFERENT FABRICATING OPERATIONS, IN PART AND IN SIMPLIFIED ABBREVIATED VERSIONS.

p 21, 1971 J. R. MGCONNELL 3,606,658

STRUCTURAL MEMBER FABRICATING PROCESS Filed May 19', 1970 2 Sheets-Sheet 2 86 4 [5/ LEU I H I a 37 1 I L fi 34 I5 35 ll L l FIG.4.

3,606,658 STRUCTURAL MEMBER FABRICATING PROCESS John R. McConnell, 148 Woodside Ave., Ridgewood, NJ. 07450 Continuation-impart of application Ser. No. 737,654, June 17, 1968. This application May 19, 1970, Ser. No. 38,668

Int. Cl. B23p 17/00, 19/00 US. Cl. 29--155R 9 Claims ABSTRACT OF THE DISCLOSURE A method is disclosed of handling and completely fabricating structural steel floor members from raw steel shapes into precisely fitting interlocking unit elements that form with the necessary columns a multiple-cell cage for the support of floors, roofs, walls and other elements. In a typical application of the process a trailer-load or car-load of raw shapes from the steel rolling mills is shunted alongside a longitudinally-disposed multiple fabricating apparatus, that includes a travelling hoist operable along a transverse overhead gantry runway spanning the apparatus and the necessary parallel delivering and shipping vehicles. Successive raw shapes are hoisted out of the delivering vehicle and lowered to the adjacent dual conveyor belts that transversely move them individually into the operating area of the dual end-located three way drills that simultaneously drill the webs and flanges of the shape near the ends for attachment of pairs of end connection angles to the web of the shape. The flange holes permit the attachment to wind-bracing brackets located on the supporting columns. The intermediately located vertically pivotable drills drill the web for floor beam connections. Moved on to the forward half of the apparatus multiple rivets attached to a lower connection angle are heated, the angle is assembled to the beam web, an upper mating connection angle is placed over the projecting rivets and plural air hammers head the rivets over the three assembled pieces of steel. This operation is performed at each end of the shape. The now completed member is lifted off the dual belts and stacked in an empty parallel vehicle for outbound shipping. This overall process is applicable to other combinations of different fabricating operations, in part and in simplified abbreviated versions.

This application is a continuation-in-part of co-pending application Ser. No. 737,654 filed June 17, 1968, Pat. No. 3,546,772.

This invention relates to an overall process for the automated mechanized fabrication of finished structural steel floor and roof members from hot-rolled homogenous steel shapes.

The principal objective of the process is economic in the immense savings in cost and time possible in the successi ve processing of scores and often hundreds of identical floor and roof beams and girders that occur in large hi-rise buildings, long bridges and viaducts and similar structures.

It is an objective of the present application to set forth an integrated and co-ordinated automatic method for the combined receiving, routing, hoisting, conveying, measuring, laying-out, assembling, complete precise fabricating and shipping of unit steel members, in a single continuing forward flow throughout the heavy material without heavy manual labor. Also elementary versions of the fabricating process are proposed that may also use an overhead crane or alternate means of handling the shapes.

Another objective is to eliminate the repetitive hoisting,

United States Patent handling, transferring and stacking of the shapes between and at various plural, progressive work areas.

One objective is to provide an integrated co-acting apparatus and system that Will take raw shapes from an inbound delivery vehicle, process them into completely finished building members and deposit them in an outbound vehicle for direct shipment to the building site.

A further objective is to provide an apparatus that will quickly process unit members of various lengths from raw shapes of shorter random lengths, as unitary end products for site assembly-erection.

For other objects and a better understanding of the invention reference may be had to the following detailed description taken in conjunction with the accompanying drawing showing typical applications in which:

FIG. 1 is a plan-layout and flow-line diagram of dual end combined drilling and riveting units and intermediate combined drilling units.

FIG. 1a is a fragmentary elevation to a large scale of the holes drilled in the flanges near the ends and intermediately thereof of the member of FIG. 1.

FIG. 2 is a plan-layout and flow-line diagram of dual end and dual intermediate flange drilling units on a common operating centre-line.

'FIG. 2a is a fragmentary elevation of the flange holes of member of FIG. 2.

FIG. 3 is a plan-layout and flow-line diagram of a simplified version of a web and flange drilling apparatus for multiple drilling near to the ends of the member of FIG. 3

FIG. 3a is a fragmentary elevation of the flange holes of member of FIG. 3.

FIG. 4 is a plan-layout and flow-line diagram of dual end fusion Welders and dual intermediate web drilling units for member of FIG. 4.

In operation, a car-load of raw shapes of ordered lengths comes in from the rolling mills. If it is a top-timepriority job it is switched directly to a position alongside the proper fabricating apparatus. The car load of identical shapes (or mixed sizes) is completely fabricated in a matter of hours and out of the shop in a delivery car or trailer.

In the maximum application of the process and apparatus the dual opposite-hand end-located fabricators are symmetrically pre-located from the centre anchorage by a common right and left threaded shaft to locate their operating centres the precise distance apart required by the member. Intermediate units would be moved separately as required. The powered hoist of the gantry crane transfers a shape to the dual conveyor belts for movement under the dual fabricating unit heads. Successive shapes, with accepted trade tolerance of one inch in length are length-centered under the operating heads by longitudinally-opposed, equally powered rams simultaneously converged. On completion of fabrication the member moves forward for outbound loading by the hoist.

The process and apparatus can perform any type of fabricating operation required in the production of floor beams and girders. All of these are performed transverse to the length of the shape. The principal operations are varied, piercing, cutting and coping of the shapes, and the assembling and securing of connection details to the main shape. These objectives would be accomplished by mechanisms within the scope of this process that would also include resistance fusion Welding, bolting and rivet heating and driving. To set forth the generalized application of the process various types of fabricators are shown in support of the plan-layouts. The process is not confined to these alone but is applicable to all the varied types of fabricating operations. The claims will be confined to the overall process and separate applications will be filed. for the various fabricating units.

FIG. 1 shows end located opposite hand dual combined three-way drilling and rivet heating-driving fabricator units 1 with intermediately located dual combined flange and web drilling units 2 located on a common two-rail track 3. Each pair of dual units are variously spaceable by powered separate threaded shafts 4 and 5 from a midlocated anchorage 6. Parallel inbound 7 and outbound 8 vehicle tracks flank the sides of the longitudinal apparatus 9 with a transverse crane rail 10 and powered trolley 11 and hoist 12 spanning the three tracks. In operation, with the vertical-arcing drill head 13 of 2 depressed the shape 14 is placed by the hoist of crane 10 on the forwardly operating conveyor belts 15 of drillerriveter 1 for end drilling by drill mechanism 16 and intermediate drilling by drill mechanism 17. Forwarded to the second stage assembling-heater-riveter 18 dual angles 19 are secured at the ends and multiple spandrel holes 20 are drilled in one flange by the intermediate drilling units 21. Forward actuation of the dual conveyor belts moves the completed member 22 forward for loading by the crane into an outbound vehicle 23.

FIG. 2 shows a simplified longitudinally extending apparatus 24 of plural flange-drilling units 25 and 26 relatively prelocateable on a common operating centre-line in a shallow pit 27. A transverse bridge crane 28 operating on two overhead longitudinal crane rails 29 permits the hoisting and precise locating of the shape 14 on dual rests 30 over and integral with the toes 31 of the fabricator bases 32 (one shown at left). The pit is ramped at the ends 27' to permit easy removal of the units by towing or self-powered means.

A further simplification of this apparatus would be the substitution of an independent extraneous means for the placement of the shape 14 on dual transverse conveyor belts 15 (one shown at right). Dual oppositely and inwardly convergible length centering rams integral with the fabricators would generally be used to longitudinally locate the shape. Completed member 22 would be removed by independent extraneous means, possibly the general main shop crane. Successive shapes would quickly follow.

FIG. 3 shows relatively-pre-locatable end-located three-way (web and two flanges) drilling units 34 guided by a floor-mounted T 37 on a common longitudinal operating centre-line.

The T equipped with a scale can be used to locate the plural fabricating units and also to clamp the units in relative positions against vibration and displacement. The floor angles 36 may be used to protect against the wear caused by movement of the units. One can be stationary or both can be self-powered or manually moved by geared hand-wheels. A shape is placed on dual transversely operable conveyor belts 15 for locating and length centering in the inwardly-facing opposite-hand fabricators operating area by equally-convergible length-centering rams (not shown). On completion of fabricating the completed member 22 is forwarded to be removed by a mobile floor crane or other extraneous means.

FIG. 4 shows relatively pre-locatable dual end-located fusion welder units and intermediately-located vertically-depressible web-drilling units 17 on a common longitudinal operating centre-line in floor mounted guide angles 36. The welder assembles and welds dual end connection-angles 19 at the ends of the shape. The operating ends of all units face inwardly to and adjacent to the shape. It is operated as described in FIG. 3.

FIGS. la to 3a show the holes drilled in the flanges by the equipment of FIGS. 1 to 3.

It is considered unnecessary to show detailed figures of the various operating units. However they are shown in the parent co-pending application Ser. No. 737,654 filed June 17, 1968 that is allowed and awaiting publication shortly and also in a concurrently tiled co-pending application covering the said detailed mechanisms. The latter is a continuation-in-part.

Unit 35 is the subject of a Pat. No. 3,401,254 and also an improvement application Ser. NO-

The process has been studied in various forms to make it widely applicable and adaptable to the whole range of the fabricating industry; its. the largest possible shops of high, steady production, medium shops of substantial output and small shops of low production. It can be completely mechanized for automation operation in new shops or it can be largely manually controlled for installation in existing shop-buildings with little or no alterations to floors or buildings, with variations for intermediate conditions.

In the latter case the investment cost can be cut drastically while providing many of the advantages with a great deal of flexibility for possible changing trade practices or a rash of jobs where customers specifications call for riveting, bolting, fusion welding or resistance welding (which as yet is not approved by the A.I.S.C.). A production line can be quickly changed from four fabricating units to two units for any of the operations listed above, that would also forestall demands for idle units being manned. Where the description calls for dual oppositehand fabricating units; with proper design, these, with quick changes of minor elements need only be oppositefacing in positioning. Where a unit breaks down on the line, with a spare unit available, the heavy general shop crane can remove it and swing the spare unit into line with minimum down time. In some layouts they can be run out and in under their own power.

These elements are illustrated and set forth in the copending mechanisms application concurrently filed herewith, to which reference is respectfully referred.

What I claim as new and desire to protect by Letters Patent of the US. is:

1. A structural member fabricating process comprising in combination the following steps:

the routing of a vehicle of raw shapes to the side of a longitudinally disposed fabricating apparatus of plural opposite-hand dual end-located fabricating units on a common operating centre line, the pre-locating of said units to required relative spacthe unloading of a shape onto dual transverse conveyor belts integral with said units, by a hoist operating along a transverse overhead beam,

the transverse forwarding of the said shape into the operating areas of the said fabricating units,

the length-centering of the shape longitudinally between said units by opposed equally-convergible rams integral with said units,

the executing of plural simultaneous fabricating operations on the shape by said units,

the transverse forwarding of the shape out of the operating area, and

the loading into a second vehicle for removal, whereby individual shapes move continuously through the co-ordinated mechanized handling, laying-out and fabricating process in one continuing handling to complete outbound members.

2. A structural member fabricating process as in claim 1 further comprising the following step:

the pre-locating of intermediately-located fabricating units to required relative spacing on the common centre-line for additional fabricating operations on the shape between the ends thereof.

3. A structural member fabricating process as in claim 2 further comprising the following steps:

the intermediate forwarding and locating of the shape into a co-ordinated second fabricating station of prelocatable plural fabricating units on a second common longitudinal operating centre-line,

the executing of plural fabricating operations on the shape at the said second station by said second station plural units.

4. A structural member fabricating process comprising in combination the following steps:

the routing of a vehicle of raw shapes to the side of a longitudinally disposed fabricating apparatus of plural opposite-hand dual end-located fabricating units on a common operating centre-line, the pre-locating of said units to required relative spacs, the unloading of a shape and precise placement by a bridge-crane hoist of said shape, in the operating area on dual rests integral with said fabricating units, the executing of plural simultaneous fabricating operations on the shape by said units, and the hoisting and transfer of the completed member to a second outbound vehicle. 5. A structural member fabricating process as in claim 4 further comprising the following step:

the pro-locating of intermediately-located fabricating units, to required relative spacing on the common centre-line for additional fabricating operations on the shape between the ends thereof. 6. A structural member fabricating process comprising in combination the following steps:

the pre-locating of the dual end-located fabricating units of a longitudinally disposed fabricating apparatus having a common operating centre-line to required relative spacing, the precise placement by independent means of a shape on dual rests integral with said fabricating units, the executing of plural simultaneous fabricating opera- -tions on the shape by the said units and the removal of the shape by said independent means. 7. A structural member fabricating process comprising in combination the following steps:

the pre-locating of the dual end-located fabricating units of a longitudinally disposed fabricating apparatus having a common operating centre-line to required relative spacing, the placement of a shape by independent means onto 6 dual transverse conveyor belts integral with said units,

the transverse forwarding of the shape into the operating areas of said units,

the length-centering of the shape longitudinally between said units by opposed equally-convergible rams integral with said units,

the executing of plural simultaneous fabricating operations on the shape by said units the transverse forwarding of the shape out of the operating area, and

the removal of the shape by said independent means.

8. A structural member fabricating process as in claim 7 further comprising the following steps:

the pre-locating of intermediately-located fabricating units to required relative spacing on the common centre-line for additional fabricating operations on the shape between the ends thereof.

9. A process by which structural shapes of any required dimensions are forwardly conveyed transversely into and out-of a longitudinally disposed fabricating apparatus of pre-locatable plural fabricating machine units aligned on a common operating centre-line in which various plural co-ordinated fabricating operations are performed by said machine units on various selected areas of the shape.

References Cited UNITED STATES PATENTS 2,142,109 1/1939 Burke 29-430 3,507,025 4/1970 Ankeney 29-155 THOMAS H. EAGER, Primary Examiner US. Cl. X.R. 29-430 

